Pile with Grout Vortex

ABSTRACT

A pile is provided for installation into earth, comprising, a shaft that includes a shaft axis, a plurality of helices, and a metal that is capable of being welded so as to securely attach the helices; the shaft is provided with an end that has been configured for successive piling; the helices are shaped so that, when the shaft is torqued, the helices screw the pile into the earth about the shaft axis; a bladed portion provide with a shaft-accommodating section, a pile securing structure, a collar, and a blade; the shaft-accommodating section of the bladed portion is shaped according to the end of the shaft; the pile securing structure is configured to cooperate with a fastener; the collar of the bladed portion is generally concentric about the shaft axis; and the blade is shaped, at least in part, to agitate grout.

FIELD OF THE INVENTION

This patent application relates to foundations using helical piles with liquid grout.

BACKGROUND OF THE INVENTION

Helical piling systems are known in the art. In such systems, a round corner square shaft with helices is torqued into the earth. The torquing action of the steel shaft creates a hole into which liquid grout is poured. When the grout solidifies, a concrete pile with steel shaft reinforcement is formed.

However, there are problems with this system. Dirt and organic material fall within the liquid grout and ultimately create voids when the grout dries, thereby weakening the pile. Additionally, the hole formed by the torquing action of the steel rod is often irregularly shaped creating an irregularly shaped concrete pile with areas of significant weakness relative to other areas. Furthermore, dirt and other debris fill in the hole as it is being formed, thereby preventing the liquid grout from filling in the entire length of the steel shaft, again creating a weakness in the pile.

The current system is directed to overcoming these and other disadvantages inherent in other piling systems.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a pile with a round corner square shaft provided with bladed portions and a plurality of helices.

FIG. 2 depicts a pile with pipes and end fittings welded thereon connected via a bladed portion.

FIG. 3 depicts a top view of a bladed portion.

FIG. 4 depicts the end fittings of a pipe piling system being fastened to each other and to a bladed portion.

FIG. 5 depicts a side view of a bladed portion that is used with a round corner square shaft.

FIG. 6 depicts the top view of a bladed portion that is used with a round corner square shaft.

FIG. 7 depicts a cross-sectional view of a pipe pile with end fittings welded to the ends.

FIG. 8 depicts a cross-sectional view of two piles being coupled together via the end fittings.

FIG. 9 depicts a perspective view of two piles placed in axial alignment so that a first end fitting can be placed into a second end fitting thereby coupling together the two piles.

FIG. 10 depicts a perspective view of an end fitting on a pipe with a cross-sectional view shown in dashed lines.

FIG. 11 depicts a top-down view of the end fitting shown in FIG. 10.

FIG. 12 depicts a perspective view of an end fitting that accepts the end fitting shown in FIG. 11 and a cross-sectional view shown in dashed lines.

FIG. 13 depicts a top-down view of the end fitting shown in FIG. 12.

FIG. 14 depicts a top-down view of an end fitting.

FIG. 15 depicts a top-down view of an end fitting.

FIG. 16 depicts a perspective view of an end fitting.

FIG. 17 depicts a top-down view of an end fitting.

FIG. 18 depicts a partial cross-sectional view and a partial perspective view of a piling.

FIG. 19 depicts a partial cross-sectional view and a partial perspective view of a piling.

FIG. 20 depicts a top-down view of an end fitting.

FIG. 21 depicts a perspective view of an end fitting.

FIG. 22 depicts a perspective view of two piles being coupled together via the end fittings.

FIG. 23 depicts a bladed portion with a single helically-shaped blade.

FIG. 24 depicts a bladed portion with a connecting stud securing two pipe piles.

SUMMARY OF THE INVENTION

The invention is defined by the claims set forth herein; however, briefly, the invention herein is a pile for installation into earth, comprising, a shaft that includes a shaft axis, a plurality of helices, and a metal that is capable of being welded so as to securely attach the helices; the shaft is provided with an end that has been configured for successive piling; the helices are shaped so that, when the shaft is torqued, the helices screw the pile into the earth about the shaft axis; a bladed portion provided with a shaft-accommodating section, a pile securing structure, a collar, and a blade; the shaft-accommodating section of the bladed portion is shaped according to the end of the shaft; the pile securing structure is configured to cooperate with a fastener; the collar of the bladed portion is generally concentric about the shaft axis; and the blade is shaped, at least in part, to agitate grout.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 depicts a preferred embodiment of the present invention; as shown therein, a pile 100 for installation into earth 300 is provided with a pile axis 101 and a bladed portion 200. The bladed portion 200 includes a plurality of blades, including a plurality of axially-extending blades 211, 212, 213, 214, and a plurality of angled blades 221, 222, 223, 224 (as is shown in FIG. 5). The bladed portion 200 of the pile 100 also includes a shaft-accommodating section 230 and a plurality of annular sections 241, 242 (“first” and “second” annular sections respectively). The axially-extending blades 211, 212, 213, 214 extend from the shaft-accommodating section 230 of the bladed portion 200 of the pile 100.

As FIG. 2 illustrates, the bladed portion 200 is provided with a first, second, third, and fourth axially extending blades (designated “211,” “212,” “213,” and “214” respectively). Though the preferred embodiment is provided with four axially-extending blades, in an alternative embodiment, a single helically-shaped blade 215 is utilized, as is shown in FIG. 23, which can be said to extend both radially and axially.

Though the blades 211, 212, 213, 214 are referred to herein as “axially-extending blades,” it bears noting that the blades extend both radially from the shaft accommodating section 230 from the second annular section 242 to the first annular section 241 and axially along the length of the of the shaft accommodating section 230 from the first annular section 241 to the second annular section 242. Thus, as FIG. 2 illustrates, the axially extending blades 211, 212, 213, 214 are triangular in shape (preferably a “right” triangle). Advantageously, the “hypotenuse” of the triangularly-shaped blade extends radially (at least in part) from the second annular section 242 to the first annular section 241. Though the blades 211, 212, 213, 214 are shown as generally flat planes that extend radially from the shaft-accommodating section, in an alternative embodiment, the blades are dished or curved (or helically-shaped).

As noted above, the bladed portion 200 of the pile 100 is provided with a plurality of angled blades 221, 222, 223, 224, each of which is provided with an angled surface (designated “225,” “226,” “227,” “228,” respectively). The angled blades 221, 222, 223, 224 are arranged about the axis 101 so that the blades extend radially (at least in part). Though the preferred embodiment is shown with angled blades 221, 222, 223, 224 that are flat, in an alternative embodiment, the angled blades 221, 222, 223, 224 are dished. In yet another alternative embodiment, the angled blades 221, 222, 223, 224 are curved; for example, the angled blades 221, 222, 223, 224 are curved so as to provide a helix. Advantageously, the angled blades 221, 222, 223, 224 (as well as the axially-extending blades 211, 212, 213, 214) are shaped to create a vortex when rotated within a column of grout.

Referring again to FIG. 5, the bladed portion 200 of the pile 100 is provided with a collar, preferably a plurality of collars 251, 252 (referred to herein as “first” and “second” collars respectively in order to distinguish one from the other). In the preferred embodiment, the collars 251, 252 are circular and concentric about the pile axis 101. As the foregoing suggests, the collars 251, 252 are provided with a plurality of radii, with the “first” collar 251 including a radius that is larger than the radius of the “second” collar 252. As the pile is torqued, the collars 251, 252 force earth and debris downward so that a generally cylindrical volume 310 is created about the pile axis 101 (as is depicted in FIG. 1).

In the preferred embodiment, the angled blades 221, 222, 223, 224 are positioned between the first collar 251 and the second collar 252 with the angled surfaces 225, 226, 227, 228 oriented to face (at least in part) the direction of rotation. The first collar 251 is provided with a pile securing structure 253 (generally designated in FIG. 6). In the preferred embodiment, the pile securing structure 253 is shaped according to the end of a pile. When the pile is in the form of a “round corner square shaft” or “RCS shaft,” as it is known in the industry, the pile securing structure 253 is provided with an opening 260 that is in the cross-sectional shape of a square. In FIG. 5, the pile securing structure is in the form of a plurality of through-holes 261, 262 defined within the shaft accommodating section 230. The through-holes 261, 262 are positioned so that they line up with holes that have been previously drilled into the shaft and are configured to cooperate with a fastener, preferably a threaded male fastener such as a bolt. Thus, the pile securing structure secures the shaft within the bladed portion 200 and allows torque to be transmitted from the shaft to the bladed portion 200.

In the case of a pipe pile (a pile that utilizes a pipe rather than an “RCS shaft”), the pile securing structure is shaped to transmit torque and secure the pipe and the bladed portion 200. As FIG. 2 and FIG. 4 illustrate, the pipe pile 120 is provided with a square-shaped end fitting (though any out-of-round shape is within the scope of the present invention). As FIG. 4 shows, the pile securing structure is dimensioned to accept at least one of the pipe pile's end fittings; more specifically, as shown in FIG. 3, the bladed portion 200 of the pile 100 is provided with an opening 231 which includes a length 287 and the width 286 that are dimensioned so that the extensions

Referring now to FIG. 4, the end fittings are dimensioned to fit within each other thereby transmitting torque from one pipe to another. The end fittings are provided with extensions (a “first” extension 201 and a “second” extension 202). The pile securing structure is provided with a fastening portion 232, which is in the form of a plurality of arms 271, 272. The arms 271, 272 have been configured to cooperate with a fastener, preferably a threaded male fastener such as a bolt. The arms 271, 272 are U-shaped; however, other shapes are permissible, such as a C-shaped arms, as well as arms provided with a simple through hole (which advantageously, could be a tapped hole).

As stated above, the bladed portion 200 of the pile 100 is provided with a shaft-accommodating section 230 that is shaped according to a connecting stud 125. In FIG. 24, a connecting stud 125 is shown. As illustrated, the connecting stud 125 is a section of an RCS shaft that is provided with a through-hole 126 (preferably a plurality) for a nut 127 and bolt 128. Thus, the shaft-accommodating section 230 is shaped according to the shaft. Accordingly, the shaft-accommodating section 230 is provided with an opening 231 that generally matches the shaft (as is shown in FIG. 6). In the preferred embodiment, both are square in cross-section.

The bladed portion 200 depicted herein is cast through use of a sand mold. The preferred embodiment is fabricated through use of lost-form casting methods, such as lost-wax casting or Styrofoam casting. Alternatively, however, the bladed portion 200 can be fabricated through heating the metal material and forging features. In this embodiment, the casting is substantially free of burs, seams, flashes and sharp edges.

FIG. 7 depicts a presently preferred embodiment of a pile 310. As shown therein, the pile 310 is provided with a first end 11 and a second end 12. As used herein, the term “end” is intended to include the extreme end, as well as portions extending from the extreme end towards the other end. The first end 11 includes a first end fitting 21 while the second end 12 is provided with a second end fitting 22. The pile 310 is also provided with a tubular section 13. In the presently preferred embodiment, the tubular section 13 is cylindrically shaped, yielding a cross-sectional shape that is circular, however, in other alternative embodiment cross-sectional shapes, such as square hexagonal, octagonal or other out-of-round shape is provided.

In use, the pile 310 is driven into the ground, preferably helically, via a hydraulic drive (not shown). After a pile is driven into the soil (referred to herein as a “driven pile”), another pile 310 is coupled thereto (referred to herein as a “following pile”). The hydraulic drive is then connected to the following pile. The following pile, together with the previously driven pile, is then helically driven into the ground (referred to herein as “successive piling”).

The first end fitting 21 is provided with a first outer dimension 23 and a first inner dimension 24 while the second end fitting 22 is provided with a second outer and a second inner dimension 26. Referring now to FIG. 8, the first end fitting 21 is shaped to cooperate with the second end fitting 22. The first outer dimension 23 of the first end fitting measures less that the second inner dimension 26 of the second end fitting 22.

As FIG. 8 illustrates, at least a portion of the first end fitting 21 fits within the second end fitting 22. Thus, when successive piling is used, the first end fitting 21 of a following pile fits into the second end fitting of the previously driven pile 310. As FIG. 9 illustrates, each of the end fittings 21, 22 is provided with a coupling extension. The coupling extensions 27, 28 on the end fittings 21, 22 are dimensioned so that tapped holes 29, 30 on each of the end fittings 21, 22 can be placed in alignment when a following pile is connected to a previously driven pile, such as through use of a threaded bolt.

Each of the coupling extensions 27, 28 is configured to transmit torque. As illustrated in FIG. 9, extensions 27, 28 are provided with a cross-sectional shape that is out-of-round, preferably square. In FIG. 16 and FIG. 17, however, end fittings are depicted with coupling extensions 27, 28 that are hexagonal in cross-sectional shape. In yet another alternative embodiment, the coupling extensions 27, 28 are octagonal in cross-sectional shape. As is also illustrated herein, each of the coupling extensions 27, 28 is provided with a first thickness 37 (as is illustrated in FIG. 11) while the pipe 40 and the tubular section 13 of FIG. 7 are provided with a second thickness. In the presently preferred embodiment, the first thickness 37 of the coupling extensions 27, 28 is greater than the second thickness 38 of the pipe 40 and the tubular section 13. Thus, a pipe or tubular section with a reduced thickness 38 has ends that are provided with a greater thickness 37.

Advantageously, the first end fitting 21 includes a plurality of first outer dimensions 23 so as to provide the coupling extension 27 with a tapered shape, preferably a tapered shape wherein the outer dimension 23 increases as the coupling extension 27 extends from the pipe-accepting end 31 (hereinafter referred to as an “increasing tapered shape”). Conversely, the second end fitting 22 includes a plurality of second inner dimensions 26 so as to provide the coupling extension 28 with a tapered shape, preferably a tapered shape wherein the inner dimension 26 decreases as the coupling extension 28 extends from the pipe-accepting end 32 (hereinafter referred to as a “decreasing tapered shape”).

It is preferred that the tapered shape of one end fitting correspond to the tapered shape of the other end fitting. Thus, in the case of the end fitting embodiments shown herein, the increasing tapered shape of the first end fitting 21 corresponds to the decreasing tapered shape of the second end fitting 22 so that when the first end fitting 21 of a following pile is placed into the second end fitting 22 of a previously driven pile, the end fittings 21, 22 are axially aligned with greater ease.

The coupling extension 27 of the first end fitting 21 is configured to be placed within the coupling extension 28 of the second end fitting 22. For greater ease in placing the coupling extension 27 of the first end fitting 21 within the coupling extension 28 of the second end fitting 22, the decreasing tapered shape of the second end fitting 22 includes a spherical surface 29, as is shown in FIG. 16.

In the presently preferred embodiment, each of the end fittings 21, 22 is provided with a pipe-accepting end. FIG. 9 depicts the first end fitting 21 with a pipe-accepting end 31 and the second end fitting 22 with a second pipe-accepting end 32. The pipe-accepting ends 31, 32 are shaped according to the cross-sectional shape of the tubular section 13 of the pile 310. Advantageously, the pipe-accepting ends 31, 32 are shaped to place the end-fitting and the tubular section in axial alignment. As FIG. 9 illustrates, the pipe-accepting ends 31, 32 are each in the form of a flange that extends to enlarged sections 33, 34 that are cylindrically shaped. FIGS. 10 and 11 depict alternative embodiments of the first and second end fittings 21, 22. As shown therein, the end fittings 21, 22 are provided with pipe-accepting ends 31, 32 that taper to reduced portions 35, 36 that are frustro-conically-shaped.

In the presently preferred embodiment, the end fittings 21, 22 are cast using a lost wax technique from steel; however, in alternative embodiments, the end fittings 21, 22 are cast in sand or lost foam. Then, the end fittings 21, 22 are welded on ends of a pipe 40. As FIGS. 8 and 9 illustrate, the enlarged sections 33, 34 extend over the ends of the pipe thereby enabling each of the end fittings 21, 22 to be welded to the external portion 41 of the pipe 40 where the flange of the end fitting meets the pipe 40 itself. However, in alternative embodiments, the pipe-accepting ends 31, 32 extend, at least in part, within the pipe, as is depicted in FIGS. 10 and 12. As illustrated therein, the reduced portions 35, 36 partially extend within the pipe 40, and end fittings and the pipe 40 are welded together where the annular portion 42 of the pipe 40 meets the reduced portions of the end fittings 21, 22.

As FIGS. 7 and 10 illustrate, a transition 43 links the coupling extension with the pipe-accepting end. Thus, the transition 43 enables the end fitting to include a plurality of cross-sectional shapes. In the presently preferred embodiment, the transition 43 links a coupling extension that is shaped to transmit with a pipe-accepting end that is shaped to place the end fitting and the tubular section in axial alignment, because the coupling extension and the pipe-accepting end of the end fittings serve different purposes, it may be advantageous to provide each with cross-sectional shapes that differ from one another. Thus, in the case of the presently preferred embodiment, the transition 43 links a coupling extension that is square in cross-sectional shape with a pipe-accepting end that is circular in cross-sectional shape. In alternative embodiments, transitions link coupling extensions that are octagonal in cross-sectional shape with pipe-accepting ends that are circular in cross-sectional shape. In still other alternative embodiments, transitions link coupling extensions and pipe-accepting ends that are provided with cross-sectional shapes that are the same but that differ in physical dimension (e.g. small squares linked with larger squares).

Referring now to FIG. 14, a piling 310 is shown looking into a first end fitting 21. As shown therein, the first end fitting 21 is provided with a plurality of enlarged portions 44, 45, 46, and 47. The enlarged portions 44, 45, 46, 47 are located where the first end fitting 21 is provided with a plurality of tapped holes (which in FIG. 14 are designated 44-a, 45-a, 46-a, 47-a). The enlarged portions 44, 45, 46, 47 and the tapped holes 44-a, 45-a, 46-a, 47-a of the first end fitting 21 cooperate with a bolt (not shown). When the first end fitting 21 is placed within a second end fitting 22 (such as the second end fitting 22 shown in FIG. 15), the enlarged portions 44, 45, 46, 47 function as a plurality of female fasteners.

When the walls 44-b, 45-b, 46-b, 47-b of the first end fitting 21 are placed within the walls 44-c, 45-c, 46-c, 47-c of the second end fitting 22 and the tapped holes 44-a, 45-a, 46-a, 47-a of the first end fitting 21 are aligned with the holes 44-d, 45-d, 46-d, 47-d of the second end fitting 22 so that bolts can be passed through, the walls 44-b, 45-b, 46-b, 47-b of the first end fitting 21 and the walls 44-c, 45-c, 46-c, 47-c of the second end fitting 22 can be shaped so as to provide a spring-effect that stretches the bolts, much as a washer stretches a bolt in a standard nut-washer-and-bolt fastening assembly. By way of example and not limitation, the walls of either the first end fitting 21 or the second end fitting 22 (or both) can bow away from each other, thereby creating a “spring-effect” when the respective walls of the end fittings 21, 22 are fastened towards each other when the bolts are torqued into the enlarged portions 44, 45, 46, 47 of the first end fitting 21.

Referring now to FIG. 16 and FIG. 17, a first end fitting 21 is shown. As illustrated, the first end fitting 21 is provided with a coupling extension 27 that is hexagonal is cross-section and a pipe-accepting end 31 that is configured to cooperate with pipes 40 having a plurality of diameters. FIG. 18 and FIG. 19 illustrate the first end fitting 21 of FIG. 16 in a partially sectionalized view and better depict the pipe-accepting end 31. As shown in FIG. 18, the pipe-accepting end 31 is welded to the annular portion 42 of the pipe 40 while in FIG. 19, the pipe-accepting end is welded to the external portion 41 of the pipe 40. The first end fitting 21 of FIG. 16 is provided with a pile guide 29 that is spherically shaped and a plurality of tapped holes 50, 51, 52 that cooperate with tapped holes provided on the second end fitting 22.

An alternative embodiment of the second end fitting 22 is depicted in FIG. 20 and FIG. 21. As shown therein the second end fitting 22 is provided with a cylindrically shaped outer wall 59, a plurality of guides 53, 54, 55, 56, 57, 58, and a plurality of tapped holes 53-a, 54-a, 55-a, 56-a, 57-a, 58-a. The guides 53, 54, 55, 56, 57, 58 are shaped to guide bolts into threaded engagement with the tapped holes 53-a, 54-a, 55-a, 56-a, 57-a, 58-a when the first end fitting 21 is placed within the second end fitting 22. In the presently preferred embodiment, the guides 53, 54, 55, 56, 57, 58 are spherically shaped and extend from the outer wall 59 towards the tapped holes 53-a, 54-a, 55-a, 56-a, 57-a, 58-a.

As illustrated in both FIG. 20 and FIG. 21, the second end fitting 22 is provided with a pile guide 29 that is shaped to place the first and second end fittings into axial alignment when successive piling is used. As shown herein, the pile guide 29 is spherically shaped; however, in alternative embodiments, the pile guide 29 is frusto-conically shaped.

While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. 

What is claimed is: 1: A pile for installation into earth, comprising, a) a shaft that includes a shaft axis, a plurality of helices, and a metal that is capable of being welded so as to securely attach the helices; b) the shaft is provided with an end that has been configured for successive piling; c) the helices are shaped so that, when the shaft is torqued, the helices screw the pile into the earth about the shaft axis; d) a bladed portion provided with a shaft-accommodating section, a pile securing structure, a collar, and a blade; e) the shaft-accommodating section of the bladed portion is shaped according to the end of the shaft; f) the pile securing structure is configured to cooperate with a fastener; g) the collar of the bladed portion is generally concentric about the shaft axis; and h) the blade is shaped, at least in part, to agitate grout. 2: A pile according to claim 1 wherein the blade extends axially from the shaft-accommodating section of the bladed portion. 3: A pile according to claim 1 wherein the collar is shaped to create a generally cylindrical volume about the shaft axis. 4: A pile according to claim 1 wherein the bladed portion has been cast through use of a sand mold. 5: A pile according to claim 1 wherein the bladed portion is fabricated through use of lost-form casting methods.
 6. A pile according to claim 1 wherein the blade is a generally flat plane that extends radially from the shaft-accommodating section. 7: A pile according to claim 1 wherein the bladed portion is further provided with an angled blade. 8: A pile according to claim 7 wherein the angled blade is arranged about the shaft axis so that the blades extend, at least in part, radially. 9: A pile according to claim 1 wherein the blade is shaped to create a vortex when rotated within a column of grout. 10: A pile for installation into earth, comprising, a) a pipe that includes an axis, a plurality of helices, and a metal that is capable of being welded so as to securely attach an end fitting; b) the end fitting has been configured for successive piling; c) the helices are shaped so that, when the shaft is torqued, the helices screw the pile into the earth about the shaft axis; d) a bladed portion provided with a shaft-accommodating section, a pile securing structure, a collar, and a blade; e) the shaft-accommodating section of the bladed portion is shaped according to the end of the shaft; f) the pile securing structure is configured to cooperate with a fastener; g) the collar of the bladed portion is generally concentric about the shaft axis; and h) the blade is shaped, at least in part, to agitate grout. 11: A pile according to claim 10 wherein the blade extends axially from the shaft-accommodating section of the bladed portion. 12: A pile according to claim 10 wherein the collar is shaped to create a generally cylindrical volume about the shaft axis. 13: A pile according to claim 10 wherein the bladed portion has been cast through use of a sand mold. 14: A pile according to claim 10 wherein the bladed portion is fabricated through use of lost-form casting methods. 15: A pile according to claim 10 wherein the blade is a generally flat plane that extends radially from the shaft-accommodating section. 16: A pile according to claim 10 wherein the bladed portion is further provided with an angled blade. 17: A pile according to claim 16 wherein the angled blade is arranged about the shaft axis so that the blades extend, at least in part, radially. 18: A pile according to claim 10 wherein the blade is shaped to create a vortex when rotated within a column of grout. 